Filter frame assembly with seal

Abstract

A filter frame assembly is disclosed comprising a perimeter member surrounding a fluid aperture adapted to accommodate a fluid flow from an upstream direction to a downstream direction, the perimeter member comprising a perimeter upstream surface, a perimeter downstream surface, and a perimeter outer surface connecting the perimeter upstream surface to the perimeter downstream surface. A gasket carrier is attached to the perimeter member and comprises a carrier outer portion facing generally away from the fluid aperture and a first outer portion sealing member projecting from the carrier outer portion.

What is claimed is: 
     
       1. A filter assembly comprising:
 a unitary perimeter member surrounding a fluid aperture adapted to accommodate a fluid flow from an upstream direction to a downstream direction, the perimeter member comprising a perimeter upstream surface extending inwardly toward the fluid aperture, a perimeter downstream surface extending inwardly toward the fluid aperture, and a perimeter outer surface connecting the perimeter upstream surface to the perimeter downstream surface; 
 a filter media spanning the fluid aperture, the filter media positioned between the perimeter upstream surface and the perimeter downstream surface with the perimeter upstream surface and the perimeter downstream surface covering at least a portion of the filter media; and 
 a gasket carrier attached to the perimeter outer surface and comprising a carrier outer portion facing generally away from the fluid aperture and a first outer portion sealing member projecting from the carrier outer portion. 
 
     
     
       2. The filter frame assembly of  claim 1  wherein the gasket carrier further comprises a carrier upstream portion generally facing the upstream direction. 
     
     
       3. The filter frame assembly of  claim 2  wherein the gasket carrier further comprises an upstream sealing member projecting from the carrier upstream portion. 
     
     
       4. The filter frame assembly of  claim 1  wherein the gasket carrier further comprises a carrier downstream portion generally facing the downstream direction. 
     
     
       5. The filter frame assembly of  claim 4  wherein the gasket carrier further comprises a downstream sealing member projecting from the carrier downstream portion. 
     
     
       6. The filter frame assembly of  claim 1  wherein the gasket carrier comprises a carrier upstream portion generally facing the upstream direction and a carrier downstream portion generally facing the downstream direction, the carrier outer portion connecting the carrier upstream portion to the carrier downstream portion. 
     
     
       7. The filter frame assembly of  claim 6  further comprising at least one of a downstream sealing member projecting from the carrier downstream portion or an upstream sealing member projecting from the carrier upstream portion. 
     
     
       8. The filter frame assembly of  claim 7  comprising both a downstream sealing member projecting from the carrier downstream portion and an upstream sealing member projecting from the carrier upstream portion. 
     
     
       9. The filter frame assembly of  claim 1  comprising a second outer portion sealing member projecting from the carrier outer portion, wherein the first outer portion sealing member is positioned more proximate the upstream direction than the second outer portion sealing member. 
     
     
       10. The filter frame assembly of  claim 1  wherein the perimeter member comprises four members arranged in a rectangle. 
     
     
       11. The filter frame assembly of  claim 10  wherein the gasket carrier comprises four portions, one portion being attached to each member of the perimeter member. 
     
     
       12. The filter frame assembly of  claim 11  wherein the four portions of the gasket carrier are not connected to one another. 
     
     
       13. The filter frame assembly of  claim 1  wherein the gasket carrier is attached to the perimeter member by an adhesive. 
     
     
       14. The filter frame assembly of  claim 1  wherein the gasket carrier is attached to the perimeter member by a clip feature. 
     
     
       15. The filter frame assembly of  claim 14  wherein the clip feature is integrally formed onto one of the gasket carrier or the perimeter member such that the clip feature slides over a clipping member on the other to secure the clip feature over the clipping member by friction. 
     
     
       16. The filter frame assembly of  claim 15  wherein the gasket carrier is sufficiently resilient to bend to permit the clip feature to slide over the clipping member. 
     
     
       17. The filter frame assembly of  claim 16  wherein the gasket carrier comprises the clip feature and the perimeter member comprises the clipping member. 
     
     
       18. The filter frame assembly of  claim 1  wherein the gasket carrier is attached to the perimeter member by a snap feature. 
     
     
       19. The filter frame assembly of  claim 18  wherein the snap feature comprises a recess on one of the perimeter member or the gasket carrier and a protrusion on the other to snap into the recess. 
     
     
       20. The filter frame assembly of  claim 19  wherein the gasket carrier is sufficiently resilient to bend to permit the protrusion and the recess to snap together. 
     
     
       21. The filter frame assembly of  claim 19  wherein the perimeter member comprises a recess and the gasket carrier comprises a protrusion. 
     
     
       22. The filter frame assembly of  claim 21  wherein the perimeter member comprises a recess on each of the perimeter upstream surface and the perimeter downstream surface; and
 wherein the gasket carrier comprises a protrusion projecting inwardly from the carrier upstream portion to snap into the recess on the perimeter upstream surface and a protrusion projecting inwardly from the carrier downstream portion to snap into the recess on the perimeter downstream surface. 
 
     
     
       23. The filter frame assembly of  claim 1  wherein the gasket carrier is attached to the perimeter member by a press feature. 
     
     
       24. The filter frame assembly of  claim 23  wherein the press feature comprises a reception channel on one of the perimeter member or the gasket carrier and a plug on the other to press into the reception channel. 
     
     
       25. The filter frame assembly of  claim 24  wherein the perimeter member comprises a reception channel and the gasket carrier comprises a plug. 
     
     
       26. The filter frame assembly of  claim 24  wherein plug comprises one or more retention features to cooperate with an inner wall of the reception channel to resist removal of the plug from the reception channel. 
     
     
       27. The filter frame assembly of  claim 1  wherein the perimeter member defines a perimeter direction along the perimeter member, wherein the gasket carrier is attached to the perimeter member by a slide feature such that the gasket carrier slides onto the perimeter member along the perimeter direction. 
     
     
       28. The filter frame assembly of  claim 27  wherein the slide feature comprises a slot on one of the perimeter member or the gasket carrier and a rail on the other to slide into the slot. 
     
     
       29. The filter frame assembly of  claim 28  wherein the perimeter member comprises a slot and the gasket carrier comprises a rail. 
     
     
       30. The filter frame assembly of  claim 28  wherein the slot and the rail cooperate in a dovetail configuration. 
     
     
       31. The filter frame assembly of  claim 6  wherein the gasket carrier comprises independent first and second carrier portions, the first carrier portion comprising a carrier upstream portion and a portion of the carrier outer portion; the second carrier portion comprising a carrier downstream portion and the remaining portion of the carrier outer portion. 
     
     
       32. The filter frame assembly of  claim 31  comprising both a downstream sealing member projecting outwardly from the carrier downstream portion and an upstream sealing member projecting outwardly from the carrier upstream portion. 
     
     
       33. The filter frame assembly of  claim 31  comprising a second outer portion sealing member projecting from the carrier outer portion, wherein the first outer portion sealing member is positioned on the first carrier portion and the second outer portion sealing member is positioned on the second carrier portion. 
     
     
       34. A filter frame assembly comprising:
 a perimeter member surrounding a fluid aperture, the perimeter member comprising a perimeter upstream surface, a perimeter downstream surface, and a perimeter outer surface connecting the perimeter upstream surface to the perimeter downstream surface; and 
 a gasket carrier attached to the perimeter member by a snap feature and comprising a carrier upstream portion, a carrier downstream portion, and a carrier outer portion connecting the carrier upstream portion to the carrier downstream portion; the gasket carrier further comprising:
 a first outer portion sealing member projecting outwardly from the carrier outer portion; 
 a downstream sealing member projecting outwardly from the carrier downstream portion; and 
 an upstream sealing member projecting outwardly from the carrier upstream portion; 
 
 the snap feature comprising a recess on each of the perimeter upstream surface and the perimeter downstream surface, a protrusion projecting inwardly from the carrier upstream portion to snap into the recess on the perimeter upstream surface, and a protrusion projecting inwardly from the carrier downstream portion to snap into the recess on the perimeter downstream surface, wherein the gasket carrier is sufficiently resilient to bend to permit the protrusions and the recesses to snap together. 
 
     
     
       35. The filter assembly of  claim 34  wherein the filter media comprises two sections arranged in a V-pattern having an open portion and a closed portion, wherein the open portion corresponds to a fluid aperture. 
     
     
       36. The filter assembly of  claim 35  wherein the filter media comprises four sections arranged in a successive V-pattern having an open portion and a closed portion, wherein each open portion corresponds to a fluid aperture. 
     
     
       37. A filter frame assembly comprising:
 a cage comprising a perimeter member surrounding at least two fluid apertures, the at least two fluid apertures being generally traversed by at least one primary cross member, at least one secondary cross member having a first end and a second end, and first and second wall members each having a first and second end, wherein each first end of each wall member is connected to the perimeter member and each second end of each wall member is respectively connected to the first and second ends of the at least one secondary cross member, the perimeter member comprising:
 a perimeter upstream surface, a perimeter downstream surface, and a perimeter outer surface connecting the perimeter upstream surface to the perimeter downstream surface; 
 
 a gasket carrier attached to the perimeter member and comprising a carrier outer portion facing generally away from the fluid apertures and a first outer portion sealing member projecting from the carrier outer portion; and 
 a filter element having at least four sections; 
 wherein the cage generally surrounds the filter element, wherein the at least four sections of the filter element are arranged in a successive V-pattern having an open portion and a closed portion, wherein each open portion corresponds to a fluid aperture and each closed portion corresponds to a secondary cross member; and 
 wherein each section of the filter element is secured in sealing relation to adjacent sections and to the cage. 
 
     
     
       38. The filter frame assembly of  claim 37 , wherein the perimeter member comprises polymeric material comprising at least one of acrylonitrile butadiene styrene, polycarbonate, or high impact polystyrene. 
     
     
       39. The filter frame assembly of  claim 37 , wherein the first and second wall members each comprise polymeric material independently comprising at least one of acrylonitrile butadiene styrene, polycarbonate, or high impact polystyrene. 
     
     
       40. The filter frame assembly of  claim 37 , wherein the sealing relation of each section of the filter element to adjacent sections and to the cage is provided at least in part by an adhesive comprising at least one of a hot melt adhesive or a curable adhesive. 
     
     
       41. The filter frame assembly of  claim 37 , wherein each of the at least four sections of the filter element is a discrete pleat pack. 
     
     
       42. The filter frame assembly of  claim 37 , wherein the perimeter member further comprises at least one male engagement feature or female reception feature, and the first end of each wall member further comprises at least one corresponding male engagement feature or female reception feature, wherein each male engagement feature is engaged with a corresponding female reception feature. 
     
     
       43. The filter frame assembly of  claim 37 , wherein the second end of each wall member further comprises at least one male engagement feature or female reception feature, and the at least one secondary cross member further comprises at least one corresponding male engagement feature or female reception feature, wherein each male engagement feature is engaged with a corresponding female reception feature. 
     
     
       44. The filter frame assembly of  claim 37 , further comprising at least one flow directing member connected to each at least one primary cross member.